Motion and Path Planning for Additive Manufacturing

1st Edition - November 21, 2023
Authors: Alex C. Roschli, Michael C. Borish, Abby K. Barnes, Thomas A. Feldhausen, Peter Wang, Eric MacDonald
Language: English
Paperback ISBN:
9 7 8 - 0 - 4 4 3 - 1 5 2 8 6 - 3
eBook ISBN:
9 7 8 - 0 - 4 4 3 - 1 5 2 8 7 - 0

Motion and Path Planning for Additive Manufacturing takes a deep dive into the concepts and computations behind slicing software – the software that uses 3D models to generate… Read more

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Motion and Path Planning for Additive Manufacturing takes a deep dive into the concepts and computations behind slicing software – the software that uses 3D models to generate the commands required to control the motion of a 3D printer and ultimately construct objects.

Starting with a brief review of the different types of motion in additive systems, this book walks through the steps of the path planning process and discusses the different types of toolpaths and their corresponding function in additive manufacturing. Planar, non-planar, and off-axis path planning are examined and explained. This book also presents pathing considerations for different types of 3D-printers, including extrusion, non-extrusion, and hybrid systems as well as 3- and 5-axis systems.

Engineers, researchers, and designers in the additive manufacturing field can use this book as a reference for every step of the path planning process, as well as a guide that explains the computations underlying the creation and use of toolpaths.

Cover image
Title page
Table of Contents
Copyright
Dedication
Preface
Chapter 1 Introduction to additive manufacturing
Abstract
The history of additive manufacturing
Taxonomy of additive manufacturing processes
Software support of additive manufacturing
Organization of text
References
Chapter 2 Mechanical systems and kinematics
Abstract
Introduction
Links, joints, and mechanisms
Mathematical representations of mechanical motion
Robot workspaces
Robot Jacobians
Conclusion
References
Chapter 3 Motion platforms and kinematic arrangements
Abstract
Introduction
Cartesian systems
Delta configurations
Six DOF robot arm configurations
Configurations in research and development
Conclusion
References
Chapter 4 Geometry data storage
Abstract
Introduction
STL file formats
ASCII
Binary
Other geometry storage file types
The OBJ file
The AMF file
The 3MF file
Comparing the other file types to the STL
3D scan data from point clouds
Conclusion
References
Chapter 5 Cross-sectioning
Abstract
Introduction
Pre-processing
Cross-sectioning
Optimizing polygons for 3D-printing
Conclusion
References
Chapter 6 Closed-loop toolpath generation
Abstract
Introduction
Finding the path location
Two-bead-width constraint
Multiples of the bead width
Hollow shapes
Edge cases
Complex path geometry
Types of closed-loop contours
Conclusion
References
Chapter 7 Space-filling toolpath generation
Abstract
Introduction
Types of space-filling toolpaths
Finding the space to fill
Space-filling toolpath settings
Fill patterns
Rectilinear
Grid infill
Hexagon-and-triangle fill
Triangle fill
Concentric
Honeycomb
Gyroid
Hilbert curve
Conclusion
References
Chapter 8 Open-loop toolpath generation
Abstract
Introduction
Geometry identification
Voronoi diagram generation
Voronoi skeleton generation
Skeleton optimization
Conclusion
References
Chapter 9 Support, raft, brim, and skirt pathing
Abstract
Introduction
Supports
Rafts
Brims
Skirts
Conclusion
References
Chapter 10 Path modifiers
Abstract
Introduction
Tip wipe
Spiral lift
Startup
Slowdown
Prestart
Conclusion
References
Chapter 11 Travels, optimizations, and ordering
Abstract
Introduction
Directionality and ordering
Travels
Layer travel insertion
Island and path travel insertion
Conclusion
References
Chapter 12 Toolpath considerations for extrusion: Pellet, filament, concrete, and thermoset
Abstract
Introduction
Thermoplastic extrusion
Thermoset extrusion
Concrete extrusion
Conclusion
References
Chapter 13 Toolpath considerations for DED: Arc and laser welding
Abstract
Introduction
Height control
Site-specific control
Advanced site-specific control
Conclusion
References
Chapter 14 Planar slicing for nonextrusion AM processes
Abstract
Introduction
The basics of slicing for non-extrusion
Data representation
Using the data
Conclusion
References
Chapter 15 Off-axis and nonplanar slicing
Abstract
Introduction
Off-axis printing
Printing via automatic off-axis computation
Nonplanar printing via conformal mapping
Conclusion
References
Chapter 16 Toolpath considerations for 5-axis systems
Abstract
Introduction
Applications for 5-axis toolpaths
Complex surfaces and surface normality
Decomposed geometries
AM discontinuity mitigation
Methods for 5-axis motion
Case study: Slicing approach for large format 5-axis motion
Conclusion
References
Chapter 17 Toolpath considerations for hybrid additive manufacturing
Abstract
Introduction
Directly manufacturing components
Feature addition
Remanufacturing operations
Conclusion
References
Chapter 18 The g-code file
Abstract
Introduction
What is g-gode?
G-code syntaxes
Motion commands
Nonmotion commands
Writing g-code from toolpaths
G-code for 5-axis systems
Conclusion
References
Chapter 19 Closing the Loop
Abstract
Introduction
Changing the slicing paradigm
Sensor feedback
Support of experimental AM systems
Support and integration of simulations
New visualization modalities
Conclusion
References
Appendix A Geometry data file examples
Appendix B G-code example files
Index

Alex C. Roschli

Alex Roschli obtained a Bachelor's and Master's Degree in Electrical Engineering from the University of Tennessee in 2015 and 2016, respectively. He has conducted research in the Manufacturing Demonstration Facility at Oak Ridge National Laboratory (ORNL) since 2012. His area of expertise and research has centered around the development of large format additive manufacturing and the BAAM (Big Area Additive Manufacturing) system. He has played an integral role in many projects such as 3D printing the first car, a Shelby Cobra, a Guinness World Record holding Boeing 777x wing blade mold, a wind turbine blade mold, and a 34' catamaran boat hull mold.

His current focus is software development for toolpath generation in additive manufacturing. This includes slicing, printing, motor and extrusion control, and closed loop data feedback. Alex manages development of ORNL Slicer 2, a novel toolpath generation software produced at ORNL.

Affiliations and expertise

Oak Ridge National Laboratory, Oak Ridge, USA

Michael C. Borish

Dr. Michael Borish is a research staff member in the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL), having joined in 2017. At the MDF, he engages in a wide range of disciplines within Computer Science as they relate to industrial additive manufacturing. This research encompasses visualization, augmented reality, path planning, and computer vision, to name a few. He hopes to expand the boundaries of what we define as manufacturing technology. He is also interested in altering established paradigms of operation particularly as it relates to slicing and path planning and has been developing custom slicing software to that end. He has also built an open-source community around slicing software to advance the state of the art in path planning for industrial additive manufacturing.

Affiliations and expertise

Post-Doctoral Researcher of Computer Science, Oak Ridge National Laboratory, Oak Ridge, USA

Abby K. Barnes

Abby Barnes is a Research Communications Professional at Oak Ridge National Laboratory's Manufacturing Demonstration Facility. She was previously a researcher in at the University of Tennessee, Knoxville. She has co-authored two research papers and contributed to five others.

Affiliations and expertise

Research Communications Professional, Oak Ridge National Laboratory's Manufacturing Demonstration Facility, Oak Ridge, USA

Thomas A. Feldhausen

Thomas Feldhausen is a research staff member and technical lead for hybrid manufacturing at Oak Ridge National Laboratory's Manufacturing Automation and Controls Group. Hybrid manufacturing, a combination of additive and subtractive (machining) manufacturing, is used in his research at ORNL's Manufacturing Demonstration Facility to provide industrial solutions for component repair, tooling and tooling repair, advanced energy systems, aerospace, and automotive applications. Thomas worked at Honeywell Federal Manufacturing in Kansas City before coming to ORNL, where he specialized in multi-axis additive processes for direct ink-write technology.

Affiliations and expertise

Research Staff Member and Technical Lead, Hybrid Manufacturing, Oak Ridge National Laboratory's Manufacturing Automation and Controls Group, Oak Ridge, USA

Peter Wang

Peter Wang is a research staff scientist in the Manufacturing Systems Design Group at Oak Ridge National Laboratory (ORNL). Prior to working at ORNL, he worked in aerospace and underground construction industries for 12 years. His previous work experience has covered mechanical and civil structural design, heavy machine design, project management and construction site automation. He obtained his PhD in 2018 from the University of California, Irvine with a focus in robot kinematics. His current research interests cover robotics, manufacturing systems development, automation, additive manufacturing, and the circular economy.

Affiliations and expertise

Researcher, Manufacturing Systems Design Group, Oak Ridge National Laboratory (ORNL), Oak Ridge, USA

Eric MacDonald

Eric MacDonald, Ph.D. is Professor of Aerospace and Mechanical Engineering and Murchison Chair at the University of Texas at El Paso, and serves as the Associate Dean of Research and Graduate Studies for the College of Engineering. Dr. MacDonald received his doctoral degree in Electrical and Computer Engineering from the University of Texas at Austin in 2002. He worked in industry for 12 years at IBM and Motorola and subsequently co-founded a start-up specializing in CAD software, which was subsequently acquired by a firm in Silicon Valley. Dr. MacDonald held faculty fellowships at NASA’s Jet Propulsion Laboratory, US Navy Research and was awarded a US State Department Fulbright Fellowship in South America. His research interests include 3D printed multi-functional applications and process monitoring in additive manufacturing with instrumentation and computer vision for improved quality and yield.

Affiliations and expertise

Professor, Aerospace and Mechanical Engineering, The University of Texas at El Paso, Texas, United States